Conductive liquid three dimensional printer

ABSTRACT

A printer that produces objects from liquid conductive material is disclosed. In one embodiment, the printhead has a chamber for containing liquid conductive material surrounded by an electromagnetic coil. A DC pulse is applied to the electromagnetic coil, resulting in a radially-inward force on the liquid conductive material. The force on the liquid conductive material in the chamber results in a drop being expelled from an orifice. In response to a series of pulses, a series of drops fall onto a platform in a programmed pattern, resulting in the formation of an object.

BACKGROUND OF THE INVENTION

Field of the Invention

Liquid metal jet printing is, in one embodiment, a type ofdrop-on-demand printing. It is similar to ink-jet printing in that adrop of liquid to be printed is dispensed from a nozzle at specificintervals to create a figure or object. Typically, a platform beneaththe nozzle moves in a pre-programmed pattern to form an object. Toproduce a pattern on the printing surface, drops are successivelyejected from the nozzle after each movement of a printhead. The timingof the movement of the nozzle is often dependent upon the time requiredto produce a drop of liquid.

In three-dimensional printing, patterns are generally repeated on aprinting surface, where successive drops on top of another eventuallyproduce a three-dimensional object. Three dimensional printing has beenmost successful, to this point, in creating plastic objects.Three-dimensional printing of metal objects has been limited in itsusefulness due to the technical difficulties in working with liquidmetal.

Various methods of producing a liquid metal drop for printing have beendeveloped. A number of devices known in the art utilize mechanical forceto propel liquid metal out of a nozzle. Mechanical force for producing adrop can be generated by various means. Some devices related to thepresent disclosure utilize piezoelectric actuators to generatemechanical force to generate a drop, such as U.S. Pat. No. 7,077,334.The '334 patent is directed to a drop-on-demand printer. The methoddescribed in the '334 patent exemplifies the use of a piezoelectricactuator to create pressure in the fluid-containing chamber of adrop-on-demand printing device. Another example of the use of apiezoelectric actuator in drop-on-demand printing is described in U.S.Pat. No. 4,828,886. Means of producing a drop other than piezoelectrichave been described in the related art. Ultrasonic means of generating adrop. Examples of this method include U.S. Pat. Nos. 3,222,776 and4,754,900, which induce vibrations at the nozzle through the use ofultrasound to produce a drop.

The related art discloses various methods by which devices have utilizedelectromagnetic coils to produce a force on liquid metal to eject liquidmetal out of a nozzle. For example, U.S. Pat. No. 6,202,734 relates to adevice for producing liquid metal drops utilizing magentohydrodynamics.The '734 patent also describes the use of electromagnetic force toproduce drop-on-demand liquid metal. The patentable improvement over therelated art described by the '734 patent generally relates to the use ofalternating current and magnetohydrodynamics in liquid metal printing.

A number of related art devices utilize a magnetic coil adjacent to theliquid metal to induce a field to impose a force on the liquid. In thesetypes of devices, the liquid carries a current flowing in a directionperpendicular to the surrounding magnetic field, thereby generating aforce. This type of device is generally known as an electromagnetic (EM)pump. EM pump devices generally rely on alternating current (AC) in themagnetic coil to produce a force on liquid metal. Examples of AC EM pumpdevices include U.S. Pat. No. 4,842,170; which describes anelectromagnetic pump applying an alternating current to anelectromagnetic coil adjacent a nozzle. U.S. Pat. No. 3,807,903describes an electromagnetic pump that relies on varying electricalcurrent to control the liquid flow from a nozzle.

U.S. Pat. Nos. 8,267,669, 4,818,185, 4,398,589; 4,566,859, 3,515,898 and4,324,266, 4,216,800 also relate to devices for electromagneticallypumping liquid metal. Generally, these devices utilize alternatingcurrent or travelling magnetic fields by physically moving permanentmagnets to impart force on a liquid metal. These devices were patentablebecause they improved upon the prior art by eliminating the need forsolid electrodes to produce a current in the metal flow. The patentableimprovements over the prior art for the '669 and '185 patents generallyrelate to the ability of the devices to create a force in the liquidmetal stream without electrodes that could corrode, or seals that couldfail.

U.S. Pat. No. 5,377,961 relates to an improvement on an electromagneticpump type device for producing drops of liquid metal. The '961 patentrelates to a soldering device for depositing small amounts of solder ona printed circuit board. The '961 device pinches off drops by amechanism that propels a drop forward and reverses force on the streamto separate the stream from the drop using an AC current applied to theliquid metal. The improvement of the '961 device relates to the reversalof force to produce a drop in a relatively short period of time. Themethod utilized by the '961 device reverses the direction of theelectric current applied to the system, causing the force exerted on thesolder stream to be substantially instantaneously reversed without thenecessity of transferring electrical energy to vibratory, ultrasonic orthe like.

The related art described above has several disadvantages. The '734patent does not utilize direct current (DC) applied to a magnetic coilto produce a force in an annular direction leading to the liquid metalbeing forced radially toward the nozzle, thereby producing a liquidmetal drop. The use of a DC pulse to produce a force simplifies theconstruction of a drop-on-demand printer. With regard to the relevantart described previously, where mechanical force is used to generate adrop, seals and moving parts are prone to wear and failure. For example,a piezoelectric actuator must be kept below its curie temperature tocontinue functioning. This requires it to be placed remotely behindinsulation and act through rods or linkages. This complexity addsfriction, risk of leakage, low performance and more expensivemaintenance requirements.

Similarly, mechanical means of displacing a drop generally involve moremoving parts, which can lead to greater wear on the device and greaterexpense. Ultrasonic methods of mechanically displacing a drop rely onthe back and forth motion induced by ultrasonic radiation. Such methodshave not been effective enough to produce an economically viable liquidmetal jet printer in the marketplace.

With regard to electromagnetic force devices, the related art describedherein generally utilizes alternating current to generate an outwardflow from the nozzle and a reverse, inward flow to displace the dropfrom the liquid stream. With the use of alternating current applied to amagnetic coil, the current must be applied in one direction and then themagnetic field must be reversed, a stepwise process that requiressignificant time, in terms of drop-on-demand printing and more complexand expensive power electronics. While related devices have addressedthis issue, none have been successful in limiting exposure of criticalparts to corrosive liquid metal which subjects such devices tosignificant and expensive wear.

SUMMARY OF THE INVENTION

The present disclosure overcomes the disadvantages of the related art.The present disclosure describes the application of a single pulse ofdirect current to an electromagnetic coil to create a radial force on aliquid conductive material. This radial force results in a drop ofliquid conductive material being expelled from a nozzle onto a platform.As the platform moves relative to the nozzle, a series of drops solidifyon the platform to form a 3D object. The present disclosure describes adevice that will not corrode or arc like related devices. Further, thedevice of the present disclosure requires fewer moving parts and is lessexpensive to build than currently existing related devices.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention and the manner in which it may be practiced isfurther illustrated with reference to the accompanying drawings wherein:

FIG. 1 shows a perspective view of the 3D printer.

FIG. 2 shows an exploded view of the internal components of theprinthead.

FIG. 3 shows a side view of the internal components of the printhead.

FIG. 4a shows a cross-sectional view taken along line 4 a from FIG. 3illustrating the internal components of the printhead.

FIG. 4b shows cross-sectional view of the lower housing taken along line4 b of FIG. 2 including the pump chamber and damping chamber.

FIG. 5 shows a side elevational view of the internal components of theprinthead including the electromagnetic coil.

FIG. 6 shows a broken away cross sectional view of the printhead.

FIG. 7 shows a broken away cross sectional perspective view the nozzle,without liquid conductive material in the chamber, illustrating the flowof inert gas.

FIG. 8 shows a broken away cross sectional perspective view the nozzlepump containing liquid conductive material.

FIG. 9 shows a schematic cross sectional view of liquid conductivematerial in the pump chamber, including the flow of liquid material outof the pump chamber and the electromagnetic coil.

FIG. 10 shows a schematic cross sectional view of the nozzle pumpincluding magnetic field lines.

FIG. 11 shows a perspective view of the nozzle pump producing dropsforming a 3D object.

DETAILED DESCRIPTION OF INVENTION

The following detailed description is merely exemplary in nature and isnot intended to limit the described embodiments or the application anduses of the described embodiments. As used herein, the word “exemplary”or “illustrative” means “serving as an example, instance, orillustration.” Any implementation described herein as “exemplary” or“illustrative” is not necessarily to be construed as preferred oradvantageous over other implementations. All of the implementationsdescribed below are exemplary implementations provided to enable personsskilled in the art to make or use the embodiments of the disclosure andare not intended to limit the scope of the disclosure, which is definedby the claims. For purposes of description herein, the terms “upper,”“lower,” “left,” “rear,” “right,” “front,” “vertical,” “horizontal,” andderivatives thereof shall relate to the invention as oriented in FIG. 1.Furthermore, there is no intention to be bound by any expressed orimplied theory presented in the preceding technical field, background,brief summary or the following detailed description. It is also to beunderstood that the specific systems and processes illustrated in theattached drawings, and described in the following specification, aresimply exemplary embodiments of the inventive concepts defined in theappended claims. Hence, specific dimensions and other physicalcharacteristics relating to the embodiments disclosed herein are not tobe considered as limiting, unless the claims expressly state otherwise.

At the outset, it should be clearly understood that like referencenumerals are intended to identify the same structural elements,portions, or surfaces consistently throughout the several drawingfigures, as may be further described or explained by the entire writtenspecification of which this detailed description is an integral part.The drawings are intended to be read together with the specification andare to be construed as a portion of the entire “written description” ofthis invention as required by 35 U.S.C. §112.

Since many modifications, variations, and changes in detail can be madeto the described preferred embodiments of the invention, it is intendedthat all matters in the foregoing description and shown in theaccompanying drawings be interpreted as illustrative and not in alimiting sense. Thus, the scope of the invention should be determined bythe appended claims and their legal equivalence.

FIG. 1 illustrates an overview of the liquid metal 3D printer 100 of thepresent invention. In the preferred embodiment, drops of liquid metalthat form a three dimensional metal object are produced by a printhead102 supported by a tower 104. The printhead 102 is affixed to verticalz-axis tracks 106 a and 106 b and can be vertically adjusted,represented as movement along a z-axis, on tower 104. Tower 104 issupported by a frame 108 manufactured from steel tubing.

Proximate to frame 108 is a base 110, formed of granite. Base 110supports a platform 112 upon which a 3D object is formed. Platform 112is supported by x-axis tracks 114 a and 114 b, which enable platform 112to move along an x-axis. X-axis tracks 114 a and 114 b are affixed to astage 116. Stage 116 is supported by y-axis tracks 118 a and 118 b,which enable stage 116 to move along a y-axis.

As a drop of molten aluminum 120 falls onto platform 112, the programmedhorizontal movement of platform 112 along the x and y axes results inthe formation of a three dimensional object. The programmed movement ofstage 116 and platform 112 along x-axis tracks 114 a and 114 b, andy-axis tracks 118 a and 118 b is performed by means of an actuator 122 aand 122 b, as would be known to a person of ordinary skill in the art.Liquid metal 3D printer 100 was designed to be operated in a verticalorientation but other orientations could also be employed.

Liquid metal 3D printer 100 requires input from external sources tocontrol its moving parts. Control and coordination of the liquid metal3D printer 100 comes from a controller which in the preferred embodimentis a computer, as would be known to one of ordinary skill in the art.The computer is used to translate electronic information into signals tocontrol the ejection of droplets, the positioning of stage 116 andplatform 112, as well as the height of printhead 102. Printhead 102 mayremain stationary in the preferred embodiment of the present invention;the movement of stage 116 and platform 112 provides sufficient range ofmotion. An inert gas supply 140 provides a pressure regulated source ofinert gas 142, such as argon, to the printhead 102 through a gas supplytube 144 to prevent the formation of aluminum oxide. FIG. 1 also shows asource of aluminum 132 and aluminum wire 130.

FIG. 2 shows an exploded view of the internal components of printhead102. Alternative embodiments may utilize aluminum in bar, rod, granularor additional forms. In alternative embodiments, any sufficientlyconductive liquid or colloidal mixture could be used in place ofaluminum with the proper adjustments to the system, as would be known byone of ordinary skill in the art. An upper pump housing 210, pumppartition 204, and lower pump housing 214 together form a first chamber,herein referred to as a pump chamber 220. The internal components shownin FIG. 2 are manufactured from a non-conductive material, which in thepreferred embodiment is boron nitride.

FIG. 3 illustrates internal components of printhead 102 assembled. Inthe preferred embodiment, the internal components of printhead 102 shownin FIGS. 2 and 3 are designed to be fitted together by clamping. Inalternative embodiments additional means of connecting individual partsof the present invention may be contemplated, and could includeadhesives, mechanical connections including screws, bolts, or othermeans as would be known to a person of ordinary skill in the art. Upperpump housing 210, pump partition 204 (shown in FIG. 2), lower pumphousing 214 assembled together form nozzle pump 300.

FIG. 4a is a cross-sectional view taken along line 4 a from FIG. 3 ofthe assembled internal components of printhead 102. FIG. 4a shows achannel 404 extending from a first end where aluminum wire 130 entersprinthead 102 and a second end where liquid aluminum leaves channel 404and enters pump chamber 220. Adjacent pump chamber 220 is nozzle 410.Surrounding channel 404 is a tundish 402.

FIG. 4b shows a cross-sectional view taken along line 4 b from FIG. 2,illustrating lower pump housing 214 and pump chamber 220. Lower pumphousing 214 has ledges 420 to prevent pump partition 204 from fallinginto pump chamber 220. Adjacent to pump chamber 220 is nozzle 410.Contained within nozzle 410 and downstream of pump chamber 220 is asecond chamber, herein referred to as a damping chamber 430. Downstreamof damping chamber 430 within the nozzle is a concentric orifice 440through which liquid conductive material is expelled.

In the preferred embodiment, located between orifice 440 and dampingchamber 430 is a surface extending radially outward and upstream oforifice 440 to the wall of damping chamber 430. An alternativeembodiment may exclude the damping chamber 430, in which case liquidaluminum would flow directly from pump chamber 220 to orifice 440.

FIG. 5 illustrates nozzle pump 300 enclosed by electromagnetic coil 510which is manufactured from copper, or alternatively tungsten, plasma orother materials known to be suitable by those of skill in the art.Electromagnetic coil 510 has positive electrical connection 504 and anegative electrical connection 506.

FIG. 6 illustrates a cross-sectional view of printhead 102, which showscooled wire inlet 608, an outer sleeve 606, and the nozzle pump 300enclosed by electromagnetic coil 510. In the preferred embodiment,aluminum wire 130 is fed into cooled wire inlet 608 and a wire guide andgas seal 610 made of copper. The aluminum wire 130 then passes throughan insulating coupler 604, made of Macor ceramic, where inert gas 142 issupplied through the melt shield gas inlet port 602, made of Macorceramic, to apply a protective inert gas 142 shield before the aluminumis melted.

Melted aluminum, or other electrically conductive liquid, flows downwardunder gravity and positive pressure exerted by inert gas 142 along alongitudinal z-axis to nozzle pump 300. Electrical heating elements 620a and 620 b, made of nichrome, heat the interior of a furnace 618, madeof firebrick, to above the 660° C. melting point of aluminum. Athermally conductive boron nitride tundish 402 transmits heat toaluminum wire 130, as supplied from a source of aluminum 132, causing itto melt as it enters nozzle pump 300.

Inert gas 142 is conveyed via melt shield gas inlet port 602 and nozzleshield gas port 630 allowing inert gas 142 to form a shield around theliquid aluminum to prevent the formation of aluminum oxide while inflight. A high purity inert gas 142 atmosphere reduces the potential forclogging as molten aluminum passes into pump chamber 220.

FIG. 7 illustrates pump chamber 220, which serves as a reservoir ofmolten aluminum, in the downstream portion of nozzle pump 300. Inert gas142, as indicated by arrows, flows inside and outside of nozzle pump300.

FIG. 8 shows molten aluminum flowing downward through upper pump housing210 around pump partition 204 to form a charge of molten aluminum 710.Charge of molten aluminum 710 is contained primarily within the pumpchamber 220, with a small amount of the molten aluminum contained inupper pump housing 210 to keep pump chamber 220 fully primed. An excessof molten aluminum in the upper section of pump chamber 220 wouldincrease the inertia of the charge of molten aluminum 710 and cause anundesirable decrease in the firing rate of nozzle pump 300. Inalternative embodiments the number of dividers in the pump partition 204may be varied.

Electromagnetic coil 510 is shaped to surround nozzle pump 300. Thepressure on the inert gas 142 inside nozzle pump 300 is adjusted toovercome much of the surface tension at the nozzle 410 in order to forma convex meniscus 810. The pre-pressure within pump chamber 220 prior toa pulse is set by inert gas 142 to create convex meniscus 810 with aspherical cap that is less than the radius of nozzle orifice 440. Thispressure is determined by Young's law as P=2×surface tension/orifice 440radius.

FIG. 9 is a simplified 3D section through nozzle pump 300 showing onlythe electromagnetic coil 510 and the charge of molten aluminum 710.Charge of molten aluminum 710 is shown at an appropriate level in pumpchamber 220 for operation. The shape of the upstream portion of chargeof molten aluminum 710 conforms to pump partition 204 and partitiondividers 206.

FIG. 9 further shows electromagnetic coil 510 shaped around nozzle pump300 in such a way as to focus magnetic field lines 940 verticallythrough charge of molten aluminum 710. Nozzle pump 300 is transparent tothe magnetic field. The electromagnetic coil 510 applies forces tocharge of molten aluminum 710 to pump liquid metal based on theprinciples of magnetohydrodynamics. A step function direct current (DC)voltage profile applied to the electromagnetic coil 510 causing arapidly increasing applied current 900 to electromagnetic coil 510,thereby creating an increasing magnetic field that follows the magneticfield lines 940. The optimal range of voltage for the pulse and currentstrength, as well as the range of time durations for the pulse, foreffective operation vary depending on the electrical resistivity of thefluid, viscosity and surface tension. The possible effective range iswide, where alternative embodiments could be optimally range from 10 to1000 volts (V) and 10 to 1000 amperes (A).

According to Faraday's law of induction, the increasing magnetic fieldcauses an electromotive force within the pump chamber 220 which in turncauses an induced current in molten aluminum 930 to flow along circularpaths through the charge of molten aluminum 710. The charge of moltenaluminum 710 has a length (L) and height (h) dictated by pump chamber220 height with an electrical resistance (R). The induced current inmolten aluminum 930 is also inversely proportional to resistance in thecharge of molten aluminum 710. A magnitude of magnetic field 910 (B)within a given time is also proportional to the DC voltage applied. Theinduced current in molten aluminum 930 (i) is proportional to the rateof change of magnitude of magnetic field 910 (d/dtB) which is itselfproportional to the DC voltage applied.

The induced current in molten aluminum 930 and the magnetic fieldproduce a resulting radially inward force on molten aluminum 920 (F),known as a Lorenz force, in a ring shaped element through the charge ofmolten aluminum 710 equal to the vector multiplication iL×B. Theradially inward force on molten aluminum 920 is proportional to thesquare of the DC voltage applied. The incremental pressure contributionby the ring shaped element is F/(L×h). An integration of the pressurecontribution of all of those elements through pump chamber 220 resultsin peak pressure (P) occurring at the inlet to the nozzle 410.

Peak pressure (P) is also proportional to the square of the DC voltageapplied. This pressure overcomes surface tension and inertia in themolten aluminum to expel the drop of molten aluminum. At the same time,the computer causes stage 116 to move to deposit the drop of moltenaluminum in the desired location on platform 112. After a pulse is sentand the drop of molten aluminum is discharged from the nozzle, dampingchamber 430 reduces the resulting negative pressure pulse, therebyallowing nozzle orifice 440 to stay filled with liquid aluminum whileawaiting the next pulse.

In alternative embodiments of the present invention, the shape of thenozzle may be varied to achieve a smooth inlet bell. In one embodiment,an efficient intrinsic electromagnetic heating mode is possible bypulsing the electromagnetic coil at approximately 20 us, 300 amps and1500 Hz. This creates sufficient heat to maintain the housing andaluminum at 750 C thereby melting the aluminum. The heat is createdthrough resistive losses in the electromagnetic coil and inductiveheating within the aluminum. Use of this heating mode eliminates theneed for any external heating system.

FIG. 10 shows patterns of magnetic field lines 940 within the charge ofmolten aluminum 710 at time equals 6 uS after the beginning of the DCpulse. The arc of the field lines is seen to be deflected due to thecurrent flowing within the charge of molten aluminum.

FIG. 11 illustrates nozzle pump 300 producing a drop of molten aluminum120 during formation of a 3D printed object 1100 on platform 112. The 3Dprinted object 1100 is the location to which molten metal droplets aredirected from nozzle 410. As each drop of molten aluminum 120 isdeposited, it solidifies, thereby increasing the volume of 3D printedobject 1100. The proper orientation of 3D printed object 1100 ismaintained by computer programs that control and coordinate the movementof platform 112.

In certain embodiments orientation of the components may be alteredthrough additional means, including, but not limited to altering theorientation of 3D printed object 1100 relative to printhead 102 andnozzle 410. Specific adjustments to 3D printed object 1100 may be madeas might occur during 5-axis or 4-axis printing. In certain embodiments,addition of materials to 3D printed object 1100 during formation mayalso facilitate proper positioning.

In certain embodiments, platform 112 may be constructed of a materialthat facilitates heating or cooling to optimize solidification of dropof molten aluminum 120 upon contact, as would be known to one ofreasonable skill in the art. Properties of platform 112 or thesurrounding environment that facilitate cooling may be adjusted for theparticular properties of drop of molten aluminum 120, or any alternativeliquid metal or conductive liquid that may be used to form a drop.

The preferred embodiment of the present invention describes a singlenozzle pump 300 of printhead 102. In alternative embodiments of liquidmetal 3D printer 100, the printhead 102 may have an array consisting ofmore than one nozzle pump 300 or more than one printhead 102. Such anarray can be assembled and controlled as would be known to one ofordinary skill in the art.

Having described the presently preferred embodiments of the invention,it is to be understood that the invention may otherwise be embodiedwithin the scope of the appended claims.

What is claimed is:
 1. A device for printing conductive material,comprising: a structure incorporating at least one first chamber toaccumulate a liquid conductive material; a partition at least partiallysubmerged in a pool of liquid conductive material in the first chamber,said pool of liquid conductive material extends continuously and withoutinterruption by gas pockets from the partition to an orifice duringoperation of the structure; wherein the pool of liquid conductivematerial is suspended above the orifice such that liquid conductivematerial does not flow out of the orifice under gravity alone; anelectromagnetic coil to produce a radially-directed electromotive forceon said liquid conductive material in response to a pulse of DC voltageapplied to the electromagnetic coil; wherein the radially-directedelectromotive force causes the liquid conductive material to flow withinthe first chamber; wherein the first chamber is adapted to direct theflow of liquid conductive material with the partition working inconjunction with the electromagnetic coil to redirect upward flow causedby the radially-directed electromotive force within the pool of liquidconductive material downward to push out a drop of liquid conductivematerial from the orifice.
 2. The device of claim 1 wherein saidstructure is generally nonconductive and has a generally cylindricalfirst chamber in fluid communication with at least one channel; saidchannel having an opening at an upstream end to receive conductivematerial from a source; wherein said conductive material generally movesfrom said upstream end in a downstream direction through said channel;said channel defines an axially extending flow region for said liquidconductive material to flow to said generally cylindrical first chamber;said generally cylindrical first chamber being enclosed by a housing,wherein said electromagnetic coil is disposed adjacent andradially-outward surrounding said housing and said generally cylindricalfirst chamber; said coil operatively arranged to produce a magneticfield being axially-directed within said first chamber resulting in saidradially-directed electromotive force being applied circumferentially tosaid liquid conductive material in said generally cylindrical firstchamber.
 3. The device of claim 2 wherein said first chamber isproximate a downstream end to a second chamber in which said liquidconductive material accumulates; said second chamber serving to dampnegative pressure on the liquid conductive material, thereby allowingsaid second chamber to remain filled with liquid conductive materialafter a drop is expelled from the opening; said second chamber openingat its downstream end to said orifice, wherein said second chamber andsaid orifice are incorporated into a generally cylindrical nozzleconcentric with and extending from said housing.
 4. The device of claim3 wherein said first chamber contains the partition to direct saidliquid conductive material from said channel to a perimeter of saidfirst chamber; said partition separating said first chamber into a lowerregion and an upper region wherein said lower region is defined as thespace between a downstream surface of said partition and a downstreamsurface of said first chamber.
 5. The device of claim 4 wherein saidpartition has a generally circular downstream section with saiddownstream surface parallel to an x-axis and a y-axis disposedradially-outward and downstream to a generally conical section; saidpartition having a set of dividers disposed proximate to and upstream ofsaid circular downstream section and said conical section; said conicalsection having a radially-inward circular partition platform parallel tothe x-axis and y-axis; said partition platform being disposed axiallydownstream of the channel opening such that liquid conductive materialexiting the downstream end of said channel contacts said partitionplatform and flows to the perimeter of said first chamber through a setof gaps between said set of dividers.
 6. The device of claim 5 whereinsaid channel is enclosed by a tundish heated by a furnace to atemperature required to melt a solid conductive material.
 7. The deviceof claim 6 wherein said first chamber is enclosed by a generally bellshaped housing having an upper housing extending radially-outward anddownstream from said channel at an approximately 45 degree angle and alower housing having a wall extending downstream from said angled upperhousing and generally parallel with said channel and a bottom extendingfrom the downstream end of the wall portion inward generallyperpendicular to said outer wall portion.
 8. The device of claim 7wherein said electromagnetic coil is disposed adjacent said nozzle andsurrounding said second chamber and orifice therein.
 9. The device ofclaim 8 wherein said channel is connected to an inlet for inert gasthereby directing inert gas to flow through the device, wherein saidinert gas pressure is regulated to maintain an appropriate meniscus ofliquid conductive material at the orifice.
 10. The device of claim 9wherein the housing is enclosed in a housing chamber; said housingchamber being connected to an inlet for inert gas allowing said inertgas to flow externally to said housing and nozzle to protect liquidconductive material from oxidation after leaving said orifice.
 11. Thedevice of claim 10, wherein said coil is disposed adjacent said nozzleand surrounding but displaced radially-outward from said orifice. 12.The device of claim 1, wherein the pool of liquid conductive material issuspended by surface tension at the nozzle.
 13. A method for printingconductive material, comprising: a. providing a partition disposed in afirst chamber; b. at least partially filling the first chamber with aliquid conductive material; c. suspending a pool of liquid conductivematerial in the first chamber; d. at least partially submerging thepartition with the pool of liquid conductive material; e. generating apulse of DC voltage in an electromagnetic coil surrounding the firstchamber; f. applying a radially-inward directed electromotive forcecircumferentially to said liquid conductive material in said firstchamber; g. the partition working in conjunction with theelectromagnetic coil to redirect an upward flow of liquid conductivematerial produced by the radially-inward directed electromotive forcedownward to push out a drop of liquid conductive material from anorifice.
 14. The method of claim 13 comprising directing the flow ofliquid conductive material in a first radially-outward direction to aperimeter of said first chamber, thereby allowing said liquid conductivematerial to flow radially-inward toward said orifice.
 15. The method ofclaim 14 further comprising filling a second cylindrical chamber,concentric and downstream to the first chamber.
 16. The method of claim15 further comprising dividing the flow of liquid conductive materialalong the partition to direct the flow of liquid conductive material toseparate sections of a perimeter of the first chamber.
 17. The method ofclaim 16 wherein an inert gas is supplied to prevent oxidation of theliquid conductive material.
 18. The method of claim 13, wherein the poolof liquid conductive material is suspended by surface tension at thenozzle.
 19. A device for printing conductive material, comprising: Asupply of solid conductive material, wherein said solid conductivematerial is fed into a structure having an upstream and a downstreamend; said structure incorporating a channel having an inlet at itsupstream end, wherein said channel incorporates a wire guide and gasseal; said channel being proximate a tundish, wherein said tundish isenclosed by a furnace; wherein said furnace heats the tundish to atemperature sufficient to melt a solid conductive material; said channelopening at its downstream end to a cylindrical first chamber in liquidcommunication with said channel; said first chamber being enclosed by agenerally bell shaped housing having an upper housing extendingradially-outward and downstream from said channel at an angle; saidfirst chamber having a lower housing comprising a wall extending in adownstream direction from said upper housing and generally parallel withsaid channel and a bottom extending from the downstream end of the wallinward and generally perpendicular to said wall; said first chambercontaining a partition to direct liquid conductive material exiting thedownstream end of said channel to a perimeter of said first chamber,wherein said partition has a generally circular section with a surfacegenerally parallel to an x-axis and a y-axis disposed radially-outwardand downstream to a generally conical section; said partition having aset of dividers disposed proximate and to and upstream said circularsection and said conical section of said partition; said conical sectionhaving a radially-inward circular partition platform generally parallelto the x-axis and y-axis; said partition platform being disposed axiallydownstream of the channel opening such that liquid conductive materialexiting the downstream end of said channel contacts said partitionplatform and flows to a perimeter of said first chamber through a set ofgaps between said set of dividers, wherein said dividers areequidistantly disposed relative to adjacent said dividers; said firstchamber being proximate at its downstream end to a second chamber; saidsecond chamber being in liquid communication with said first chamber;said second chamber serving to damp negative pressure on the liquidconductive material, thereby allowing said second chamber to remainfilled with liquid conductive material; said second chamber having anorifice at its downstream end to expel a drop of liquid conductivematerial; said second chamber and said orifice being incorporated into agenerally cylindrical nozzle concentric with and extending downstreamsaid housing; an electromagnetic coil disposed adjacent andradially-outward said housing and surrounding said first chambertherein; said coil being operable to produce a magnetic field beingaxially-directed within said first chamber resulting in aradially-directed electromotive force applied circumferentially to saidliquid conductive material; wherein said electromagnetic coil is furtherdisposed adjacent said nozzle and surrounding said second chamber andorifice therein and displaced radially-outward from said orifice; saidelectromagnetic coil receiving a pulse of DC voltage resulting in theradially-directed electromotive force on said liquid conductivematerial; said channel being connected to an inlet for an inert gasthereby directing the inert gas to flow through the device; said housingbeing enclosed in a housing chamber; said housing chamber beingconnected to an additional inlet for inert gas allowing said inert gasto flow around said housing and said nozzle to prevent oxidation of saidliquid conductive material; the partition at least partially submergedin a pool of liquid conductive material; said pool of liquid conductivematerial extending continuously and without interruption from thepartition to an orifice during operation of the structure; wherein thepool of liquid conductive material is suspended above the orifice bysurface tension at the nozzle such that liquid conductive material doesnot flow out of the orifice under gravity alone; wherein the firstchamber is adapted to direct a flow of liquid conductive material,produced in response to a pulse of DC voltage applied to theelectromagnetic coil, with the partition working in conjunction with theelectromagnetic coil to redirect an upward flow of liquid conductivematerial caused by the radially-directed electromotive force within thepool of liquid conductive material downward to push out a drop of liquidconductive material from the orifice.